System and Method for Flexible Conversion of Feedstock to Oil and Gas

ABSTRACT

A feedstock flexible process for converting feedstock into oil and gas includes (i) indirectly heated hydrous devolatilization of volatile feedstock components, (ii) indirectly heated thermochemical conversion of fixed carbon feedstock components, (iii) heal integration and recovery, (iv) vapor and gas pressurization, and (v) vapor and gas clean-up and product recovery. A system and method for feedstock conversion includes a thermochemical reactor integrated with one or more hydrous devolatilization and solids circulation subsystems configured to accept a feedstock mixture, comprised of volatile feedstock components and fixed carbon feedstock components, and continuously produce a volatile reaction product stream therefrom, while simultaneously and continuously capturing, transferring, and converting the fixed carbon feedstock components to syngas.

RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication No. 61/556,048, filed Nov. 4, 2011, whose contents areincorporated by reference in their entirety.

FIELD OF THE INVENTION

The current invention is directed towards a continuous, scalable,feedstock flexible, cost-effective, energy integrated,feedstock-to-crude oil and syngas conversion process and apparatuscomprising: continuous indirectly heated hydrous devolatilization ofvolatile feedstock components; continuous indirectly heatedthermochemical carbon conversion of fixed carbon feedstock components;heat integration and recovery; vapor and gas pressurization; and, vaporand gas clean-up and product recovery.

The current invention also is directed towards a feedstock conversionsystem comprised of one or more hydrous devolatilization and solidscirculation subsystems integrated together with a thermochemical reactorthat act in cooperation to accept a feedstock mixture, comprised ofvolatile feedstock components and fixed carbon feedstock components, andcontinuously produce a volatile reaction product stream from thevolatile feedstock components, while simultaneously and continuouslycapturing and transferring the fixed carbon feedstock components to areactor where they may be continuously thermochemically reacted andconverted into syngas. The two product streams are useful in producingfuels, power and chemicals.

BACKGROUND OF THE INVENTION

There are many biological and chemical platforms to convert biomass intovaluable products; however, most of these technologies can only converta narrow range of biomass types into a limited number of products. Incontrast, the thermochemical platform can convert a broad spectrum ofcarbonaceous feedstock (biomass, energy crops, agri-waste, animal waste,refuse derived fuel or RDF, etc.) into a wide range of downstreamvalue-added products. In the thermochemical domain, there exist manyprocesses such as pyrolysis, thermal depolymerization, catalyticcracking, gasification, synthesis and upgrading and hybrid processessuch as gasification and fermentation for converting feedstocks intofuels, power and chemicals. Scalability, feedstock flexibility, costeffectiveness (capital and operating and maintenance costs), catalysttype, integrity, cost and life (in case of catalytic processes), lessthan satisfactory product attributes (quality, stability, acidity andimpurity, for example with some pyrolysis bio-oils) etc. are factorsthat hamper the commercialization and deployment of many of thesetechnologies. To foster the development and growth of sustainableregional economies, there is a need for a process and apparatus thataddresses the following:

-   -   Feedstock availability, variability, quality and cost—feedstock        cost has a direct and significant impact on the return on        investment (ROI) and so the higher this cost the lower the ROI.        Higher capacity feedstock conversion systems tend to be        generally more cost-effective due to scale but require access to        large feedstock supply. Feedstock availability increases with        distance from the site but transportation cost increases with        distance as well resulting in higher feedstock cost for larger        feedstock throughput units. Feedstocks of interest here        (biomass, energy crops, agri-waste, animal waste, refuse derived        fuel or RDF, etc.) tend to vary in quality, composition and        availability with time (seasonally, monthly, weekly or daily        depending upon the type) and this poses problems for systems        designed for a specific feedstock. This renders it beneficial        for a process or system that permits simultaneous processing of        multiple feedstocks and also at smaller scales (say 20 to 250        ton per day feedstock throughput).    -   Simplicity of feed system—many thermochemical systems operate at        elevated pressure and in some cases at elevated temperature as        well and require a feed system that can provide a good seal        against process gas backflow or leak into the ambient via the        feed bin. This has implications for feed system selection,        complexity, reliability, availability and cost. This renders it        beneficial to operate at slightly below ambient pressure in the        feed zone.    -   Continuous process—this is preferred to batch type process for        improved economics.    -   Intermediates production—Fuel and/or chemical production systems        generally are more cost effective at larger scale; however,        feedstock availability and cost restrict the feedstock        conversion system to smaller scale. A prudent approach then is        to produce chemical intermediates of higher value than the        feedstock in the front end for subsequent processing at larger        scale to the final product.    -   Product attributes—the higher the quality, stability, integrity,        and purity of the intermediates produced, the higher the        marketability and revenue, and in turn the viability of the        system.    -   Catalyst—catalysts facilitate process operation at milder        conditions and improve process performance but are subject to        degradation via poisoning, deactivation, attrition, pore        plugging, etc. This affects catalyst integrity and life and in        turn adds operating cost; disposal of the contaminant laden or        spent catalyst can be an issue and can entail a disposal cost.        The more exotic the catalyst, the higher the capital and        operating costs. This renders it beneficial to operate without a        catalyst or at best with a very inexpensive and disposable        catalyst.

SUMMARY OF THE INVENTION

In one aspect, the present invention is directed to an energyintegrated, continuous feedstock-to-crude oil and syngas conversionprocess comprising the following steps and components:

(1) continuous indirectly heated hydrous devolatilization of volatileportion of feedstock; (2) continuous indirectly heated thermochemicalconversion of non-volatile carbonaceous portion of feedstock; (3) heatintegration and recovery; (4) vapor and gas pressurization; (5) vaporand gas clean-up and product recovery.

The continuous hydrous devolatilization process is preferably carriedout at slightly below atmospheric pressure (0.65 to 1 bar or 9.5 to 14.5psia) and moderate temperature (320 to 569.99° C., depending upon thefeedstock chemistry). This affords the luxury of: (1) minimizingfeedstock delivery system complexity and capital cost attributed to therequirement to seal against gas backflow; and, (2) maximizing volatilereaction product quality and release rate to maximize crude oilproduction. In other non-limiting embodiments, the continuous hydrousdevolatilization process may be carried out at higher pressures (0.65 to2 bar or 9.5 to 29 psia). The char generated in the process isthermochemically converted via steam reforming and partial oxidationreactions at an elevated temperature (500 and 1400 degrees ° C.,depending upon the char properties and feedstock chemistry) to generatesyngas. The continuous thermochemical conversion process is preferablycarried out at slightly below atmospheric pressure (0.65 to 1 bar or 9.5to 14.5 psia). However, in other non-limiting embodiments, thecontinuous thermochemical conversion process may be carried out atelevated pressures (0.65 to 2 bar or 9.5 to 29 psia). Particleseparators, such as cyclones, are utilized in stages to separate solidparticulates from gaseous vapor streams. The volatile reaction productand syngas streams are preferably each cooled separately, as necessaryto above the dew point of any condensable vapors they may contain, andeither separately or combined and routed for pressurization to slightlyabove atmospheric pressure. The operating pressure ratio preferentiallyranges between 1.5 and 3, and more preferentially ranges between 2 and2.5. A steam jet ejector is preferred but mechanical compressiondevices, such as rotary blowers, gear pumps, reciprocating pistondevices may be used; however, from an operational standpoint, steam jetejectors are preferred due to lack of moving parts and excellentcontinuous operational stability and reliability. The streams then aretransferred either separately or in combined mode through solids removaland gas cleaning steps to capture fine particulates, condense thehydrocarbon volatiles into crude oil, and capture one or more of othercontaminants present including but not limited to HCl, HCN, NH₃, H₂S,and COS. The end products are crude oil and syngas which, the latterbeing rich in H₂ and CO, may be used in a wide array of downstreamsyngas processing technologies including, but not limited to: fuelethanol production using catalytic or anaerobic fermentation processes;electricity generation via gas turbine or fuel cell or gas engines;Fischer-Tropsch synthesis for production of waxes and synthetic dieselfuel; hydrogen production utilizing pressure swing adsorption ormembrane systems; or, chemicals production.

Separating the overall conversion process into devolatilization andthermochemical conversion steps facilitates the following: (1) rapid andexcellent mixing of feedstock and bed solids thus promoting fastdevolatilization of volatile feedstock components resulting in greatervolatile yield; and, (2) improved and faster carbon conversion due toreduced concentration and partial pressure of species such as H₂ and COin the thermochemical reactor which tend to inhibit char reactionkinetics.

In another aspect, the present invention is directed towards a feedstockconversion system having thermochemical reactor integrated with one ormore hydrous devolatilization and solids circulation systems configuredto accept a feedstock mixture, comprised of volatile feedstockcomponents and fixed carbon feedstock components, and continuouslyproduce a volatile reaction product stream therefrom, whilesimultaneously and continuously capturing, transferring, and convertingthe fixed carbon feedstock components to syngas.

The feedstock conversion system comprises: a reactor having a fluid bed;a dense-phase solids transport conduit connected at a first end to thefluid bed of the reactor and at a second end to a devolatilizationchamber; said dense-phase bed solids transport conduit configured toconvey bed solids from the reactor to said devolatilization chamber;said devolatilization chamber connected at a first end to thedense-phase bed solids transport conduit and at a second end to a riser;said devolatilization chamber configured to receive a feedstock andfluidization media; said riser connected at a first end to saiddevolatilization chamber and at a second end to a coarse separationdevice; said riser configured to convey bed solids and volatile reactionproducts to the coarse separation device; said coarse separation deviceis also connected to a coarse separation device discharge conduit and toa coarse separation device dipleg; said coarse separation device,configured to accept said bed solids and said volatile reactionproducts, and in response output a coarse mixed stream via a coarseseparation device discharge conduit, the coarse mixed stream comprisinga volatile reaction products and char; said coarse separation devicedischarge conduit is connected at a first end to said coarse separationdevice and at a second end to a fine separation device; said fineseparation device is also connected to a fine separation devicedischarge conduit and to a fine separation device dipleg; said coarseseparation device discharge conduit is configured to transport thecoarse mixed stream to said fine separation device; said fine separationdevice, configured to accept said coarse mixed stream, and in responseoutput a fine mixed stream via a fine separation device dischargeconduit, the fine mixed stream comprising volatile reaction products;said fine separation device configured to receive a said coarse mixedstream, and in response separate a char stream therefrom which isconveyed to the reactor via a fine separation device dipleg; said fineseparation device dipleg is connected at a first end to the fineseparation device and at a second end to the reactor, the fineseparation device dipleg is configured to convey the separated charstream from the fine separation device to the reactor; said coarseseparation device is configured to receive a mixture of said bed solidsand said volatile reaction products and separate said mixture into anintermediate solids mixture which is conveyed to the dense fluid bed ofthe reactor; a coarse separation device dipleg is connected at a firstend to the coarse separation device and at a second end to the reactor,the coarse separation device dipleg is configured to convey theintermediate solids mixture from the coarse separation device to thedense fluid bed of the reactor; a gas-solids flow regulator interposedbetween said coarse separation device dipleg's first end connected tocoarse separation device and said coarse separation device dipleg'ssecond end to the reactor; said reactor, configured to receive a saidintermediate solids mixture and, in response to said intermediate solidsmixture, output a particulate-laden syngas stream via a reactordischarge conduit; said reactor includes heating conduits to supply someor all of the endothermic heat of reaction for the steam reformingprocess; said reactor containing a primary cyclone providing internalsolids recycle into the reactor to retain bed solids and enhance carbonconversion; an optional secondary cyclone separates fly ash solids fromthe particulate-laden syngas stream; wherein: the dense-phase bed solidstransport conduit, the devolatilization chamber, the riser, the coarseseparation device, the coarse separation device dipleg, the gas-solidsflow regulator, the coarse separation device discharge conduit, the fineseparation device, the fine separation device dipleg, and the fineseparation device discharge conduit, together form a hydrousdevolatilization and solids circulation subsystem.

Definitions

Before the disclosed process is described, it is to be understood thatthe aspects described herein are not limited to specific embodiments,apparatus, or configurations, and as such can, of course, vary. It isalso to be understood that the terminology used herein is for thepurpose of describing particular aspects only and, unless specificallydefined herein, is not intended to be limiting.

As used herein the term “carbonaceous feedstock” is a material that has“fixed carbon feedstock components” and “volatile feedstock components”.

As used herein the term “fixed carbon feedstock components” refers tofeedstock components present in a carbonaceous feedstock other thanvolatile feedstock components, contaminants, ash or moisture. Fixedcarbon feedstock components are usually solid combustible residueremaining after the removal of moisture and volatile feedstockcomponents from a carbonaceous feedstock.

As used herein the term “volatile feedstock components” refers tocomponents within a carbonaceous feedstock other than fixed carbonfeedstock components, contaminants, ash or moisture.

As used herein the term “syngas” refers to a gaseous mixture containingcarbon monoxide (CO), hydrogen (H₂), and other vapors/gases, alsoincluding char, if any and usually produced when a carbonaceous materialreacts with steam (H₂O), carbon dioxide (CO₂) and/or oxygen (O₂).

As used herein the term “volatile reaction products” refers to vapor orgaseous non-polar organic species that were once present in a solid orliquid state as volatile feedstock components of a carbonaceousfeedstock wherein their conversion or vaporization to the vapor orgaseous state was promoted by the process of hydrous devolatilization.Volatile reaction products may contain both, noncondensable species, andcondensable species which are desirable for collection and refinement.

As used herein the term “hydrous devolatilization” refers to anendothermic thermochemical process wherein volatile feedstock componentsof a carbonaceous feedstock are converted primarily into volatilereaction products in a steam and hydrogen environment; however somesyngas can be generated. Typically this sub classification of athermochemical process involves the use of steam as a fluidizationmedium and involves temperatures ranging from 320 and 569.99° C.,depending upon the feedstock chemistry. Hydrous devolatilization permitsrelease and thermochemical reaction of volatile feedstock componentsleaving the fixed carbon feedstock components mostly unreacted asdictated by kinetics.

As used herein the term “steam reforming” refers to a thermochemicalprocess comprising a specific chemical reaction where steam reacts witha carbonaceous feedstock to yield syngas. The main reaction isendothermic wherein the operating temperature range is between 570 and900° C., depending upon the feedstock chemistry.

As used herein the term “partial oxidation” refers to a thermochemicalprocess wherein substoichiometric oxidation of a carbonaceous feedstocktakes place to generate syngas. By limiting the amount of oxygenavailable, the main reaction is exothermic wherein the operatingtemperature range is between 500 and 1400° C., depending upon thefeedstock chemistry.

The disclosed process can be configured by the formulator to meet thedesired need. The disclosed process provides several unmet advantages toconvert varying types of carbonaceous feedstocks into valuable endproducts.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention and to show how thesame may be carried out in practice, reference will now be made to theaccompanying drawings, in which:

FIG. 1 shows a continuous energy integrated feedstock-to-crude oilconversion process comprised of a feedstock conversion system thatincludes an indirectly heated thermochemical reactor and two hydrousdevolatilization and solids circulation subsystems, integrated togetherwith a heat integration and recovery system, and a vapor and gaspressurization system in accordance with one embodiment of the presentinvention;

FIG. 2 shows a flow chart of high level operations in the feedstockconversion system with regard to the thermochemical reactor and thehydrous devolatilizer and solids circulation subsystem in accordancewith one embodiment of the present invention;

FIG. 3 shows a feedstock conversion system including a thermochemicalreactor integrated with a plurality of hydrous devolatilization andsolids circulation subsystem in accordance with one embodiment of thepresent invention;

FIG. 4 shows options for different system combinations and permutationsrelevant to the overall continuous energy integrated feedstock-to-crudeoil conversion process.

DETAILED DESCRIPTION Reactor

FIG. 1 illustrates an energy integrated continuous feedstock-to-crudeoil conversion process (2000) comprised of three process sequence steps:Sequence Step A, Hydrous Devolatilization and Thermochemical Conversion(A); Sequence Step B, Heat Removal and Recovery (B); and, Sequence StepC, Vapor and Gas Pressurization (C). A fourth step, Sequence Step D,Vapor and Gas Clean-up and Product Recovery (D) is not shown but can beimplemented using systems and methods known to those skilled in the art.

The preferred embodiment, as depicted in FIG. 1 , illustrates SequenceStep A, Hydrous Devolatilization and Thermochemical Conversion (A)comprising a feedstock conversion system (1800) that includes a reactor(1500) and a first and second hydrous devolatilization and solidscirculation subsystem (2025 a & 2025 b).

The preferred embodiment of Sequence Step B, Heat Removal and Recovery(B) includes a sharing of heat, in the form of steam (200), generatedfrom a water source (100), between a reaction product heat recoverysteam generator (HRSG) (8025) and a syngas heat recovery steam generator(HRSG) (8050) followed by the joining of Sequence Step B ReactionProduct Discharge (B1-OUT) with Sequence Step B Syngas Discharge(B2-OUT) to form a Sequence Step B Combined Syngas and Reaction ProductDischarge (B-OUT).

The preferred embodiment of Sequence Step C, Vapor and GasPressurization (C) includes providing the Sequence Step B CombinedSyngas and Reaction Product Discharge (B-OUT) to a steam jet ejector(8035) together with at least a portion of the steam (300) generated inSequence Step B to provide the negative pressure required for SequenceStep A. Excess steam (400) generated in the system can be used for otherpurposes.

As illustrated in FIG. 1 , the feedstock conversion system (1800)includes a reactor (1500) integrated together with a first and secondhydrous devolatilization and solids circulation subsystem (2025 a & 2025b) which cooperate to realize the continuous devolatilization of firstand second volatile feedstock components (1590 ya & 1590 yb) within afirst feedstock (1590 a) and a second feedstock (1590 b) and allow forcontinuous capture, transference and conversion of the fixed carbonfeedstock components (1590 xa &1590 xb) into syngas in the reactor(1500). The numerical identifier 1590 x signifies the “fixed carbonfeedstock components” within a carbonaceous feedstock (1590). Thenumerical identifier 1590 xa signifies the “fixed carbon feedstockcomponents” within a first carbonaceous feedstock (1590 x). Thenumerical identifier 1590 xb signifies the “fixed carbon feedstockcomponents” within a second carbonaceous feedstock (1590 x). Thenumerical identifier 1590 y signifies the “volatile feedstockcomponents” within a carbonaceous feedstock (1590). The numericalidentifier 1590 ya signifies the “volatile feedstock components” withina first carbonaceous feedstock (1590). The numerical identifier 1590 ybsignifies the “volatile feedstock components” within a secondcarbonaceous feedstock (1590).

With two hydrous devolatilization and solids circulation subsystems(2025 a & 2025 b), the conversion system is capable of handlingdifferent feedstocks (1590 a, 1590 b), one input to eachdevolatilization chamber (1000 a, 1000 b). The feedstocks may differ inthroughput, composition and moisture content. In addition, due to thepresence of separate devolatilization chambers (1000 a, 1000 b),separate coarse separation devices (1300 a, 1300 b) and separate fineseparation devices (1300 a, 1300 b), the different feedstocks may besubject to separate sets of processing conditions. This maximizeshydrous devolatilization of the different volatile feedstock components(1590 ya, 1590 yb) into volatile reaction products (1375 a, 1375 b).

Each hydrous devolatilization and solids circulation subsystem (2025 a &2025 b) is comprised of a dense-phase solids transport conduit (1215 a &1215 b), a devolatilization chamber (1000 a & 1000 b), a riser (1200 a &1200 b), a coarse separation device (1300 a & 1300 b), a coarseseparation device discharge conduit (1612 a & 1612 b), a coarseseparation device dipleg (1400 a & 1400 b), a gas-solids flow regulator(1505 a & 1505 b), a fine separation device (1350 a & 1350 b), a fineseparation device discharge conduit (1365 a & 1365 b), and a fineseparation device dipleg (1355 a & 1355 b).

In one embodiment, the reactor (1500) is a thermochemical reactor tocarry out steam reforming and/or partial oxidation reactions. Thereactor (1500) may be a fluidized bed of a circulating, turbulent,entrained flow, or bubbling type and with or without indirect heatingmeans. FIG. 1 shows one embodiment of a reactor (1500) taking the formof an indirectly heated thermochemical reactor. The reactor (1500)contains a dense fluid bed (1510) including bed solids (1520), afluidization media (1530) supplied through a fluidization mediadistributor (1540), a solids drain system (1550), heating conduits(1570) which may be, for example, heat pipes, pulse heater tailpipes,electrical heater rods in thermowells, or a heat exchanger, a freeboardzone (1560), and a primary cyclone (1580). The fluidization media (1530)that enters through the fluidization media distributor (1540) maycomprise an oxygen-containing gas such as air, enriched air, oxygen,steam, CO₂, N₂, or a mixture thereof. The dense fluid bed (1510) maycontain inert material or catalyst or sorbent or engineered particles.The engineered particles may be made of alumina, zirconia, sand, olivinesand, limestone, dolomite, or catalytic materials, any of which may behollow in form, such as microballoons or microspheres. These engineeredparticles enhance mixing, heat and mass transfer, and reaction betweenthe fluidization media (1530) and the fixed carbon feedstock components(1590 x), also known as char, returned to the reactor (1500) from thehydrous devolatilization and solids circulation subsystem (2025 a & 2025b). The preferred bed solids are alumina microspheres. In someembodiments, the bed solids include Geldart Group A or Group Bparticles.

The reactor (1500) dense fluid bed (1510) temperature may range between500 and 1400° C., depending upon the reactivity, size and ash fusioncharacteristics of the fixed carbon feedstock components (1590 x)returned to the dense fluid bed (1510) from the solids circulationsystem.

The freeboard zone (1560) provides an entrained solids flow zone toimprove carbon conversion. Preferably the freeboard zone (1560) operatesin an auto-thermal or partial oxidation mode to convert the carbon inthe char to a product gas that may contain CO, CO₂, H₂, H₂O, and othergases. The reactor (1500) freeboard zone (1560) pressure may range from0.65 to 2 bar or 9.5 to 29 psia depending upon the partial oxidationefficiency requirements within the freeboard zone (1560) and thepressure coupling between the reactor (1500) and the devolatilizationchamber (1000 a & 1000 b). Multiple reactant fluid addition stages(1585) in the freeboard zone (1560), above the dense fluid bed (1510),may be included to enhance intimate gas-solid contact and promote carbonconversion reactions. The reactant fluid added through stages (1585) mayinclude air, enriched air, oxygen, steam or a mixture thereof.

In the embodiment shown in FIG. 1 , the primary cyclone (1580) islocated internal to the reactor (1500) freeboard zone (1560). In otherembodiments (not shown), the primary cyclone (1580) may be locatedexternal to the reactor (1500) freeboard zone (1560). In someembodiments, some other particle separation device is used in lieu ofone or more of the cyclones used in the feedstock conversion system(1800).

The primary cyclone (1580) is connected to a reactor discharge conduit(1602) and to a primary cyclone dipleg (1582). The primary cyclone(1580) is configured to accept gas and solids from the freeboard zone(1560) and in response output a particulate-laden syngas stream (1600)via a reactor discharge conduit (1602). Char (1522) and bed solids(1520) are recycled back to the dense fluid bed (1510) via a primarycyclone dipleg (1582) wherein the char (1522) may be converted withinthe reactor (1500) and the bed solids (1520) may be reused. Theparticulate-laden syngas stream (1600) is comprised of syngas and flyash solids (1920).

The reactor discharge conduit (1602) is connected at a first end to theprimary cyclone (1580) and at a second end to a secondary cyclone(1900). The secondary cyclone (1900) is also connected to a secondarycyclone discharge conduit (1915) and to a secondary cyclone dipleg(1925). The secondary cyclone (1900) is configured to accept theparticulate-laden syngas stream (1600), and in response output aparticulate-depleted syngas stream (1910), or a Sequence Step A SyngasDischarge (A2-OUT), via a secondary cyclone discharge conduit (1915).The particulate-depleted syngas stream (1910) is primarily comprisedsyngas and is depleted of fly ash solids (1920). Fly ash solids (1920)are separated from particulate-laden syngas stream (1600) and areconveyed from the system via a secondary cyclone dipleg (1925).

It is to be understood that in some cases the secondary cyclonedischarge conduit (1915), the particulate-depleted syngas stream (1910),and the secondary cyclone (1900), may not be required to realize aSequence Step A Syngas Discharge (A2-OUT).

Hydrous Devolatilization and Solids Circulation

Bed solids (1520) within the reactor (1500) are conveyed through thedense-phase solids transport conduit (1215 a & 1215 b) where they enterthe devolatilization chamber (1000 a & 1000 b) and merge with afeedstock (1590 a & 1590 b) and fluidization media (1630 a & 1630 b)prior to entering a riser (1200 a & 1200 b) for conveyance to a coarseseparation device (1300 a & 1300 b).

A dense-phase solids transport conduit (1215 a & 1215 b) is connected ata first end to the dense fluid bed (1510) of the reactor (1500) and at asecond end to a devolatilization chamber (1000 a & 1000 b).

As seen in the embodiment of FIG. 1 , the dense-phase solids transportconduit (1215 a & 1215 b) preferably includes a downwardly declinedtransfer entrance section (1210 a & 1210 b) connected at one end to thedevolatilization chamber (1000 a & 1000 b) and the other end to areactor nozzle (1260 a & 1260 b) at the interface with the reactor(1500). The reactor nozzle (1260 a & 1260 b) and dense-phase solidstransport conduit (1215 a & 1215 b) are preferably angled decliningdownwards so that gravity may assist conveyance of hot bed solids (1520)in a dense phase from the dense fluid bed (1510) and into thedevolatilization chamber (1000 a & 1000 b). The reactor nozzle (1260 a &1260 b) is located preferably in the upper part of the dense fluid bed(1510).

The devolatilization chamber (1000 a & 1000 b) is connected at a firstend to the dense-phase solids transport conduit (1215 a & 1215 b) and ata second end to a riser (1200 a & 1200 b). The devolatilization chamber(1000 a & 1000 b) is preferably a refractory-lined pressure vessel, aswith all the associated conduits, piping and equipment within thefeedstock conversion system (1800), and contains bed solids (1520), afluidization media (1630 a & 1630 b) supplied through a fluidizationmedia distributor (1640 a & 1640 b), a solids drain system (1650 a &1650 b), and is configured to receive a feedstock (1590 a & 1590 b),preferably a feedstock mixture, comprised of volatile feedstockcomponents (1590 y) and fixed carbon feedstock components (1590 x). Thefluidization media (1630 a & 1630 b) is preferably steam; however, itmay also include recycled syngas, an oxygen-containing gas, such as air,enriched air, oxygen, CO₂, or an inert gas such as N₂, or mixturesthereof. Steam and/or recycled syngas is the preferred fluidizationmedia (1630 a & 1630 b) to promote: (1) hydrogenation of contaminantssuch as chlorine, sulfur, or nitrogen in the feedstock and facilitateimproved water solubility; (2) water-gas reactions; (3) deoxygenation toprovide improved product quality, stability and purity; and, (4)reduction in the acidity of the condensible volatile hydrocarbon streamproduced. The solids transferred from the reactor (1500) via conduit(1215 a & 1215 b) (i) supply the energy for sensible heating of thefeedstock and for drying and devolatilizing the feedstock, and (ii) aidin manipulating the mean density and size of the combined solids orintermediate solids mixture (1655) so that it corresponds to GeldartGroup A or Group B particles and flows relatively smoothly through thecoarse separation device dipleg (1400 a & 1400 b). The fluidizationmedia (1630 a & 1630 b) fluidizes and reacts and together with thevapors and gases generated therein entrains and conveys transferredsolids and feedstock solid residue or char in a dilute-phase transportmode from the devolatilization chamber (1000 a & 1000 b) into the riser(1200 a & 1200 b) and to the coarse separation device (1300 a & 1300 b).

The devolatilization chamber (1000 a & 1000 b) is also configured toaccept a sorbent (1695 a & 1695 b) including, but not limited to, earthmetal oxides, such as sodium oxide (Na₂O), potassium oxide (K₂O),magnesium oxide (MgO), or calcium oxide (CaO), or the like to capturechlorine, sulfur or other contaminants. In one embodiment, sorbents maybe added to the devolatilization chamber (1000 a & 1000 b) and the spentsorbent may be withdrawn and regenerated.

The purpose of the devolatilization chamber (1000 a & 1000 b) is toallow enhanced contact and mixing of the feedstock (1590 a & 1590 b),fluidization media (1630 a & 1630 b), optional sorbent (1695 a & 1695b), and bed solids (1520) as well as to increase the residence time tomaximize devolatilization of the volatile feedstock components (1590 ya& 1590 yb) to form volatile reaction products (1375 a & 1375 b). In oneembodiment, the devolatilization chamber (1000 a & 1000 b) contains aconical-shaped reducer portion (1625 a & 1625 b) in the upper part totransition into the riser to facilitate a gradual change from densephase flow to dilute phase transport flow.

Feedstock (1590 a & 1590 b) is injected in the lower section of theconstant cross-sectional portion (1635 a & 1635 b) of thedevolatilization chamber (1000 a & 1000 b), near the same relativevicinity of the fluidization media distributor (1640 a & 1640 b); thissection operates at relatively low velocity to permit greater residencetime for larger feedstock particles to heat up, dry, and devolatilize.The devolatilization chamber (1000 a & 1000 b) temperature may rangebetween 320 to 569.99° C., depending upon feedstock characteristics,generally increasing with an increase in feedstock fixed carbon content.The solids transfer rate via conduit (1215 a & 1215 b) will vary withfeedstock characteristics, feed rate and the operating temperatures ofthe reactor (1500) and the devolatilization chamber (1000 a & 1000 b).

The riser (1200 a & 1200 b) is configured to convey a mixture of reactedfeedstock (1590 a & 1590 b) components, fluidization media (1630 a &1630 b), sorbent (1695 a & 1695 b), bed solids (1520), and volatilereaction products (1375 a & 1375 b) to a coarse separation device (1300a & 1300 b). Volatile reaction products (1375 a & 1375 b) continue to begenerated along the vertical length of the riser (1200 a & 1200 b) asthe volatile feedstock components (1590 ya & 1590 yb) are volatilized byintimate contact with the hot bed solids (1520).

The coarse separation device (1300 a & 1300 b) is connected to a coarseseparation device discharge conduit (1612 a & 1612 b) and to a coarseseparation device dipleg (1400 a & 1400 b). The coarse separation device(1300 a & 1300 b) is configured to accept a mixture of solids, vapor andgas, and in response output a coarse mixed stream (1610 a & 1610 b) viaa coarse separation device discharge conduit (1612 a & 1612 b). Thecoarse mixed stream (1610 a & 1610 b) comprises volatile reactionproducts (1375 a & 1375 b) and char.

The fine separation device (1350 a & 1350 b) is connected to a fineseparation device discharge conduit (1365 a & 1365 b) and to a fineseparation device dipleg (1355 a & 1355 b). The coarse separation devicedischarge conduit (1612 a & 1612 b) is configured to transport thecoarse mixed stream (1610 a & 1610 b) to said fine separation device(1350 a & 1350 b). The fine separation device (1350 a & 1350 b) isconfigured to accept the coarse mixed stream (1610 a & 1610 b), and inresponse output a fine mixed stream (1380 a & 1380 b) via a fineseparation device discharge conduit (1365 a & 1365 b), the fine mixedstream (1380 a & 1380 b) comprising volatile reaction products (1375 a &1375 b). If the feedstock conversion system (1800) is equipped with morethan one hydrous devolatilization and solids circulation subsystem (2025a & 2025 b), each fine separation device discharge conduit (1365 a &1365 b) may be joined together into a single fine separation devicedischarge conduit (1365) or a Sequence Step A Reaction Product Discharge(A1-OUT).

The fine separation device (1350 a & 1350 b) is configured to receivecoarse mixed stream (1610 a & 1610 b), and in response separate a charstream (1360 a & 1360 b) therefrom which is conveyed to the reactor(1500) via a fine separation device dipleg (1355 a & 1355 b). The fineseparation device dipleg (1355 a & 1355 b) is connected at a first endto the fine separation device (1350 a & 1350 b) and at a second end tothe reactor (1500). The fine separation device dipleg (1355 a & 1355 b)is configured to convey the char stream (1360 a & 1360 b) separated fromthe coarse mixed stream (1610 a & 1610 b) to the reactor (1500).

Most or all of the volatile feedstock components (1590 ya & 1590 yb) arereacted with the fluidization media (1630 a & 1630 b) and volatilizedinto volatile reaction products (1375 a & 1375 b) and discharged fromthe coarse separation device (1300 a & 1300 b). An intermediate solidsmixture (1655 a & 1655 b) of the fixed carbon feedstock components (1590xa & 1590 xb), sorbent (1695 a & 1695 b), and bed solids (1520) are thenconveyed from the coarse separation device (1300 a & 1300 b) to thereactor (1500) via a coarse separation device dipleg (1400 a & 1400 b).

The coarse separation device dipleg (1400 a & 1400 b) is connected at afirst end to the coarse separation device (1300 a & 1300 b) and at asecond end to the reactor (1500), and is configured to convey theintermediate solids mixture (1655 a & 1655 b) from the coarse separationdevice (1300 a & 1300 b) to the dense fluid bed (1510) of the reactor(1500).

As seen in FIG. 1 , the coarse separation device dipleg (1400 a & 1400b) includes a vertical dipleg upper section (1402 a & 1402 b) connectingto an angled dipleg lower section (1404 a & 1404 b) provided with adipleg nozzle (1440 a & 1440 b) that is flush with the internal wall atthe interface with the reactor (1500). The coarse separation devicedipleg (1400 a & 1400 b) may include at least one or more strategicallyplaced aeration port (1410 a & 1410 b), and the vertical dipleg uppersection (1402 a & 1402 b) may include at least one or more speciallydesigned slug breakers (1420 a & 1420 b), to avoid slug formation andthe consequent unsteady solids down flow, and one or more expansionjoints (not shown). Suitable nozzles, aeration ports and slug breakersare known to those skilled in the art, as exemplified by U.S. PatentPublication No. 2012/0111109A1, also WO 2012/061742A1.

In one embodiment, a gas-solids flow regulator (1505 a & 1505 b) isinterposed between the vertical dipleg upper section (1402 a & 1402 b)and the angled dipleg lower section (1404 a & 1404 b). The gas-solidsflow regulator (1505 a & 1505 b) is equipped with a fluidization mediadistributor (1414 a & 1414 b) configured to accept a fluidization media(1412 a & 1412 b) which may comprise steam, recycled syngas, CO₂, N₂, ora mixture thereof; however, steam or recycled syngas is preferred. Thefluidization media distributor (1414 a & 1414 b) may be biased in thesense that it preferentially provides a greater flow of fluidizationmedia (1412 a & 1412 b) to the vicinity closer to the angled dipleglower section (1404 a & 1404 b) than near the vertical dipleg uppersection (1402 a & 1402 b). It is preferred to have a greater superficialfluidization velocity nearby the vicinity where the angled dipleg lowersection (1404 a & 1404 b) conveys the intermediate solids mixture (1655a & 1655 b) from the vessel and to the reactor (1500) in relation to thevicinity within the vessel where the intermediate solids mixture (1655 a& 1655 b) is transferred to the vessel from the coarse separation device(1300 a & 1300 b); this is because downward transference of solids isimproved with increased fluidization, and gas bypassing up the verticaldipleg upper section (1402 a & 1402 b) is minimized with a lesserfluidization velocity. Typically, the superficial fluidization velocitymay range from slightly less than minimum fluidization velocity to lessthan two times the minimum fluidization velocity. The fluidization media(1412 a & 1412 b) allows the intermediate solids mixture (1655 a & 1655b) to flow in a dense-phase transport mode en route to the reactor(1500), thus improving solids transfer while circumventing thepropensity for clogging and slug flow. This also aids in minimizing gasleakage or backflow from the reactor (1500) through the coarseseparation device (1300 a & 1300 b). It is preferable to maintain aconstant level (1422 a & 1422 b) of solids within the gas-solids flowregulator (1505 a & 1505 b) by regulating fluidization and aeration flowrates to ensure steady flow of intermediate solids mixture (1655 a &1655 b) into the reactor (1500). It is also preferable that the verticaldipleg upper section (1402 a & 1402 b) is disposed within the gas-solidsflow regulator (1505 a & 1505 b) to transfer the intermediate solidsmixture (1655 a & 1655 b) beneath the constant level (1422 a & 1422 b)of solids to minimize gas bypassing up the vertical dipleg upper section(1402 a & 1402 b). It is also preferable to transfer the intermediatesolids mixture (1655 a & 1655 b) from the vertical dipleg upper section(1402 a & 1402 b) into the gas-solids flow regulator (1505 a & 1505 b)such that the opening in the vertical dipleg upper section (1402 a &1402 b) points away from the angled dipleg lower section (1404 a & 1404b); this is to further minimize gas bypassing up the vertical diplegupper section (1402 a & 1402 b).

System Flow Chart

FIG. 2 shows a flow chart depicting the process for a single secondhydrous devolatilization and solids circulation subsystem (2025 a)integrated with one reactor (1500) to create volatile reaction productsand syngas.

In step 10002, hot bed solids (1520) within the reactor (1500) areconveyed through a dense-phase bed solids transport conduit (1215 a)where they enter the devolatilization chamber (1000 a).

In step 10004, the devolatilization chamber (1000 a) accepts afluidization media (1630 a) and a feedstock (1590 a), preferentially afeedstock mixture, comprised of volatile feedstock components (1590 ya)and fixed carbon feedstock components (1590 xa), such as unsortedplastic and carbonaceous refuse derived fuel (RDF), municipal solidwaste (MSW), or a mixture of plastic materials, medical waste, sewagesludge, animal waste such as poultry litter, swine waste etc. or othercomplex organic materials and carbonaceous materials. In response to thehot bed solids (1520) from the reactor (1500) and the fluidization media(1630 a), the volatile feedstock components (1590 ya) undergo hydrousdevolatilization thus in turn generating volatile reaction products(1375 a).

In step (10006), the solids, reactants and volatile reaction productsare conveyed in an upward direction, against gravity, through the riser(1200 a), wherein hydrous devolatilization reactions continue tocompletion, or near completion, thus forming volatile reaction products(1375 a).

In step (10008), a coarse separation device (1300 a) separates a coarsemixed stream (1610 a) comprising volatile reaction products (1375 a) andfixed carbon feedstock components (1590 xa) to form an intermediatesolids mixture (1655 a) comprising bed solids (1520) and fixed carbonfeedstock components (1590 xa). Further, a fine separation device (1350a) further separates volatile reaction products (1375 a) from a charstream (1360 a).

In step (10010) the separated intermediate solids mixture (1655 a) flowsdown through the coarse separation device dipleg (1400 a) and into thereactor (1500) and a separated char stream (1360 a) from the fineseparation device (1350 a) flows down through the fine separation devicedipleg (1355 a) and into the reactor (1500).

In step (10012), the reactor (1500) produces a particulate-laden syngasstream (1600) from the separated fixed carbon feedstock components (1590xa) via steam reforming and/or partial oxidation reactions. Further, aprimary cyclone (1580) recycles bed solids (1520) and char (1522) to thereactor (1500).

In optional step (10014), an optional secondary cyclone (1900) separatesthe particulate-depleted syngas stream (1910) from the fly ash solids.

Alternate System Configurations

FIG. 3 illustrates another embodiment of the feedstock conversion system(1800) including an indirectly heated thermochemical reactor (1500), anda plurality of hydrous devolatilization and solids circulationsubsystems (2025 a & 2025 b & 2025 c & 2025 d).

Like the embodiment described in FIG. 1 , the embodiment depicted inFIG. 3 includes a reactor (1500) that outputs a particulate-laden syngasstream (1600), or a Sequence Step A Syngas Discharge (A2-OUT), byreacting the fixed carbon feedstock components (1590 x). However, thefeedstock conversion system (1800) depicted in FIG. 3 depicts fourhydrous devolatilization and solids circulation subsystems (2025 a &2025 b & 2025 c & 2025 d) integrated together with one common reactor(1500).

Each separate devolatilization chamber (1000 a & 1000 b &1000 c & 1000d) may accept its own feedstock (1590 a & 1590 b & 1590 c & 1590 d), andseparately volatilize and generate volatile reaction products (1375 a &1375 b & 1375 c & 1375 d) therefrom. A plurality of volatile reactionproducts (1375 a & 1375 b & 1375 c & 1375 d) may be independentlyproduced and enjoined together into a common fine separation devicedischarge conduit (1365), or a Sequence Step A Reaction ProductDischarge (A1-OUT), that contains a vapor and gas reaction product(1375) mixture comprised of a cumulative amalgam of each independentreaction product (1375 a & 1375 b & 1375 c & 1375 d). The commonthermochemical reactor (1500) accepts the fixed carbon feedstockcomponents transferred from each separate subsystem's coarse separationdevice dipleg (1400 a & 1400 b & 1400 c & 1400 d) and fine separationdevice dipleg (1355 a & 1355 b & 1355 c & 1355 d) and resultantlyoutputs a common reactor particulate-laden syngas stream (1600), or aSequence Step A Syngas Discharge (A2-OUT).

In some instances, as depicted in FIG. 3 , a total of four hydrousdevolatilization and solids circulation subsystems (2025 a & 2025 b &2025 c & 2025 d) may be used, however, as few as one may be used.Preferably, each hydrous devolatilization and solids circulationsubsystem's dense-phase solids transport conduit (1215 a & 1215 b & 1215c & 1215 d) draw bed solids (1520) from the thermochemical reactor(1500) at polar equidistant locations positioned around thecircumference of the common thermochemical reactor (1500); for example,in the embodiment of FIG. 3 , four separate hydrous devolatilization andsolids circulation subsystems (2025 a & 2025 b & 2025 c & 2025 d) areshown, so therefore it is preferred that each dense-phase solidstransport conduit (1215 a & 1215 b & 1215 c & 1215 d) be spaced 90degrees apart from one another. For the embodiment depicted in FIG. 1 ,wherein two separate hydrous devolatilization and solids circulationsubsystems (2025 a & 2025 b) are shown, it would be preferred that eachdense-phase solids transport conduit (1215 a & 1215 b) be spaced 180degrees apart from one another.

The feedstock conversion system (1800) of FIG. 3 permits processing ofmultiple feedstocks simultaneous and at varying feedstock throughputs,scales, composition and moisture content.

FIG. 4 depicts the sequence steps of the energy integrated continuousfeedstock-to-crude oil conversion process (2000) and illustrates varyingcombinations and permutations associated with integrating each processstep with one another.

Sequence Step A, Hydrous Devolatilization and Thermochemical Conversion(A) accepts a feedstock (1590) and may output either: a Sequence Step AReaction Product Discharge (A1-OUT) and a Sequence Step A SyngasDischarge (A2-OUT); or a Sequence Step A Combined Syngas and ReactionProduct Discharge (A-OUT).

Sequence Step A Combined Syngas and Reaction Product Discharge (A-OUT)is defined as the combination of aforesaid (A1-OUT) and (A2-OUT) intoone common stream; Sequence Step A Combined Syngas and Reaction ProductDischarge (A-OUT) is synonymously termed Sequence Step B Combined Syngasand Reaction Product Inlet (B-IN).

Sequence Step A Reaction Product Discharge (A1-OUT) is synonymous withSequence Step B Reaction Product Inlet (B1-IN) and the terminology usedhere indicates the transfer across the control volume boundary betweenSequence Step A, Hydrous Devolatilization and Thermochemical Conversion(A) and Sequence Step B, Heat Removal and Recovery (B).

Sequence Step A Syngas Discharge (A2-OUT) is synonymous with SequenceStep B Syngas Inlet (B2-IN) and the terminology used here indicates thetransfer across the control volume boundary between Sequence Step A,Hydrous Devolatilization and Thermochemical Conversion (A) and SequenceStep B, Heat Removal and Recovery (B).

Sequence Step B, Heat Removal and Recovery (B) may accept either: aSequence Step B Reaction Product Inlet (B1-IN) and a Sequence Step BSyngas Inlet (B2-IN); or a Sequence Step B Combined Syngas and ReactionProduct Inlet (B-IN).

Sequence Step B, Heat Removal and Recovery (B) may output either: aSequence Step B Reaction Product Discharge (B1-OUT) and a Sequence StepB Syngas Discharge (B2-OUT); or a Sequence Step B Combined Syngas andReaction Product Discharge (B-OUT).

Sequence Step B Combined Syngas and Reaction Product Discharge (B-OUT)is defined as the combination of aforesaid (B1-OUT) and (B2-OUT) intoone common stream; Sequence Step B Combined Syngas and Reaction ProductDischarge (B-OUT) is synonymously termed Sequence Step C Combined Syngasand Reaction Product Inlet (C-IN).

Sequence Step B Reaction Product Discharge (B1-OUT) is synonymous withSequence Step C Reaction Product Inlet (C1-IN) and the terminology usedhere indicates the transfer across the control volume boundary betweenSequence Step B, Heat Removal and Recovery (B) and Sequence Step C,Vapor and Gas Pressurization (C).

Sequence Step B Syngas Discharge (B2-OUT) is synonymous with SequenceStep C Syngas Inlet (C2-IN) and the terminology used here indicates thetransfer across the control volume boundary between Sequence Step B,Heat Removal and Recovery (B) and Sequence Step C, Vapor and GasPressurization (C).

Sequence Step C, Vapor and Gas Pressurization (C) may accept either: aSequence Step C Reaction Product Inlet (C1-IN) and a Sequence Step CSyngas Inlet (C2-IN); or a Sequence Step C Combined Syngas and ReactionProduct Inlet (C-IN).

Sequence Step C, Vapor and Gas Pressurization (C) may output either: aSequence Step C Reaction Product Discharge (C1-OUT) and a Sequence StepC Syngas Discharge (C2-OUT); or a Sequence Step C Combined Syngas andReaction Product Discharge (C-OUT).

Sequence Step C Combined Syngas and Reaction Product Discharge (C-OUT)is defined as the combination of aforesaid (C1-OUT) and (C2-OUT) intoone common stream; Sequence Step C Combined Syngas and Reaction ProductDischarge (C-OUT) is synonymously termed Sequence Step D Combined Syngasand Reaction Product Inlet (D-IN).

Sequence Step C Reaction Product Discharge (C1-OUT) is synonymous withSequence Step D Reaction Product Inlet (D1-IN) and the terminology usedhere indicates the transfer across the control volume boundary betweenSequence Step C, Vapor and Gas Pressurization (C) and Sequence Step D,Vapor and Gas Clean-up and Product Recovery (D).

Sequence Step C Syngas Discharge (C2-OUT) is synonymous with SequenceStep D Syngas Inlet (D2-IN) and the terminology used here indicates thetransfer across the control volume boundary between Sequence Step C,Vapor and Gas Pressurization (C) and Sequence Step D, Vapor and GasClean-up and Product Recovery (D).

Sequence Step D, Vapor and Gas Clean-up and Product Recovery (D) mayaccept either: a Sequence Step D Reaction Product Inlet (D1-IN) and aSequence Step D Syngas Inlet (D2-IN); or a Sequence Step D CombinedSyngas and Reaction Product Inlet (D-IN).

Sequence Step D, Vapor and Gas Clean-up and Product Recovery (D) mayoutput either: a Sequence Step D Reaction Product Discharge (D1-OUT) anda Sequence Step D Syngas Discharge (D2-OUT); or a Sequence Step DCombined Syngas and Reaction Product Discharge (D-OUT).

Although the invention has been described with regard to certainpreferred embodiments which constitute the best mode presently known tothe inventors, it should be understood that various changes andmodifications as would be obvious to one having an ordinary skill in theart may be made without departing from the scope of the invention whichis defined solely by the appended claims.

TABLE OF REFERENCE NUMERALS

-   devolatilization chamber (1000 a & 1000 b)-   riser (1200 a & 1200 b)-   downwardly declined transfer entrance section (1210 a & 1210 b)-   dense-phase solids transport conduit (1215 a & 1215 b)-   reactor nozzle (1260 a & 1260 b)-   coarse separation device (1300 a & 1300 b)-   fine separation device (1350 a & 1350 b)-   fine separation device dipleg (1355 a & 1355 b)-   char stream (1360 a & 1360 b)-   fine separation device discharge conduit (1365 a & 1365 b)-   volatile reaction products (1375 a & 1375 b)-   fine mixed stream (1380 a & 1380 b)-   coarse separation device dipleg (1400 a & 1400 b)-   vertical dipleg upper section (1402 a & 1402 b)-   angled dipleg lower section (1404 a & 1404 b)-   aeration ports (1410 a & 1410 b)-   fluidization media (1412 a & 1412 b)-   fluidization media distributor (1414 a & 1414 b)-   constant level (1422 a & 1422 b)-   slug breakers (1420 a & 1420 b)-   dipleg nozzle (1440 a & 1440 b)-   reactor (1500)-   gas-solids flow regulator (1505 a & 1505 b)-   dense fluid bed (1510)-   bed solids (1520)-   char (1522)-   fluidization media (1530)-   fluidization media distributor (1540)-   solids drain system (1550)-   freeboard zone (1560)-   heating conduits (1570)-   primary cyclone (1580)-   primary cyclone dipleg (1582)-   fluid addition stages (1585)-   feedstock (1590 a & 1590 b)-   fixed carbon feedstock components (1590 x)-   volatile feedstock components (1590 y)-   particulate-laden syngas stream (1600)-   reactor discharge conduit (1602)-   coarse mixed stream (1610 a & 1610 b)-   coarse separation device discharge conduit (1612 a & 1612 b)-   conical-shaped reducer portion (1625 a & 1625 b)-   fluidization media (1630 a & 1630 b)-   constant cross-sectional portion (1635)-   fluidization media distributor (1640 a & 1640 b)-   solids drain system (1650 a & 1650 b)-   intermediate solids mixture (1655 a & 1655 b)-   sorbent (1695 a & 1695 b)-   feedstock conversion system (1800)-   secondary cyclone (1900)-   particulate-depleted syngas stream (1910)-   secondary cyclone discharge conduit (1915)-   fly ash solids (1920)-   secondary cyclone dipleg (1925)-   energy integrated continuous feedstock-to-crude oil conversion    process (2000)-   hydrous devolatilization and solids circulation subsystem (2025 a &    2025 b)-   reaction product heat recovery steam generator (HRSG) (8025)-   syngas heat recovery steam generator (HRSG) (8050)-   steam jet ejector (8035)-   water source (100)-   steam (200)-   steam (300)-   steam (400)-   Sequence Step A, Hydrous Devolatilization and Thermochemical    Conversion (A)-   Sequence Step B, Heat Removal and Recovery (B)-   Sequence Step C, Vapor and Gas Pressurization (C)-   Sequence Step D, Vapor and Gas Clean-up and Product Recovery (D)-   Sequence Step A Reaction Product Discharge (A1-OUT)-   Sequence Step A Syngas Discharge (A2-OUT)-   Sequence Step A Combined Syngas and Reaction Product Discharge    (A-OUT)-   Sequence Step B Reaction Product Inlet (B1-IN)-   Sequence Step B Syngas Inlet (B2-IN)-   Sequence Step B Combined Syngas and Reaction Product Inlet (B-IN)-   Sequence Step B Reaction Product Discharge (B1-OUT)-   Sequence Step B Syngas Discharge (B2-OUT)-   Sequence Step B Combined Syngas and Reaction Product Discharge    (B-OUT)-   Sequence Step C Reaction Product Inlet (C1-IN)-   Sequence Step C Syngas Inlet (C2-IN)-   Sequence Step C Combined Syngas and Reaction Product Inlet (C-IN)-   Sequence Step C Reaction Product Discharge (C1-OUT)-   Sequence Step C Syngas Discharge (C2-OUT)-   Sequence Step C Combined Syngas and Reaction Product Discharge    (C-OUT)-   Sequence Step D Reaction Product Inlet (D1-IN)-   Sequence Step D Syngas Inlet (D2-IN)-   Sequence Step D Combined Syngas and Reaction Product Inlet (D-IN)-   Sequence Step D Reaction Product Discharge (D1-OUT)-   Sequence Step D Syngas Discharge (D2-OUT)-   Sequence Step D Combined Syngas and Reaction Product Discharge    (D-OUT)

1. (canceled)
 2. (canceled)
 3. (canceled)
 4. (canceled)
 5. A feedstockconversion system for producing synthetic crude oil from a feedstock,the system comprising: an indirectly-heated hydrous devolatilizationsystem configured to produce a coarse mixed stream containing char andvolatile reaction products; a fine separation device configured toseparate the volatile reaction products from char in the coarse mixedstream to create a fine mixed stream and a char stream; and a gasclean-up system configured to condense at least a portion of thevolatile reaction products in the fine mixed stream to produce syntheticcrude oil.
 6. The feedstock conversion system of claim 5, wherein thesystem is configured to operate continuously.
 7. The feedstockconversion system of claim 5, comprising: two indirectly-heated hydrousdevolatilization systems, each receiving a different feedstock; and twofine separation devices, each returning a respective fine mixed streamto the gas clean-up system.
 8. A feedstock conversion system configuredto produce synthetic crude oil from a feedstock, the system having ahydrous devolatilization and solids circulation subsystem comprising: afirst devolatilization chamber connected at a first end to a source forthe feedstock and at a second end to a riser; the riser connected at afirst end to said first devolatilization chamber and at a second end toa coarse separation device; the coarse separation device connected to acoarse separation device discharge conduit and to a coarse separationdevice dipleg; the coarse separation device discharge conduit connectedat a first end to a coarse separation device and at a second end to afine separation device; and the fine separation device connected to afine separation device discharge conduit and to a fine separation devicedipleg.
 9. The feedstock conversion system according to claim 8, whereinthe first devolatilization chamber further comprises fluidization media,optional sorbent, and bed solids.
 10. The feedstock conversion systemaccording to claim 8, wherein the first devolatilization chamber isconfigured to receive the feedstock and fluidization media and generatefirst volatile reaction products.
 11. The feedstock conversion systemaccording to claim 8, wherein the riser is configured to convey bedsolids and first volatile reaction products to a the coarse separationdevice.
 12. The feedstock conversion system according to claim 8,wherein the coarse separation device is configured to accept bed solids,fixed carbon feedstock components, and first volatile reaction productsand, in response, output a coarse mixed stream via a coarse separationdevice discharge conduit, wherein the coarse mixed stream comprisesfirst volatile reaction products and char.
 13. The feedstock conversionsystem according to claim 12, wherein the coarse separation devicedischarge conduit is configured to transport the coarse mixed stream tothe fine separation device.
 14. The feedstock conversion systemaccording to claim 12, wherein the fine separation device is configuredto accept the coarse mixed stream and, in response output, a fine mixedstream via a fine separation device discharge conduit, wherein the finemixed stream comprises first volatile reaction products.
 15. Thefeedstock conversion system according to claim 12, wherein the fineseparation device is configured to receive the coarse mixed stream and,in response, separate a char stream therefrom which is conveyed to thereactor via a fine separation device dipleg.
 16. The feedstockconversion system according to claim 15, wherein the fine separationdevice dipleg is configured to convey the separated char stream from thefine separation device to a reactor.
 17. The feedstock conversion systemaccording to claim 8, wherein the coarse separation device is configuredto accept bed solids, fixed carbon feedstock components, and firstvolatile reaction products and separate into an intermediate solidsmixture comprising bed solids and fixed carbon feedstock components. 18.(canceled)
 19. (canceled)
 20. (canceled)
 21. (canceled)
 22. (canceled)23. (canceled)
 24. The feedstock conversion system according to claim 8,having a feedstock inlet configured to receive feedstock at a pressurebelow ambient pressure.
 25. The feedstock conversion system according toclaim 8, wherein the hydrous devolatilization and solids circulationsubsystem further comprising: a second devolatilization chamberconfigured to generate second volatile reaction products.
 26. Thefeedstock conversion system according to claim 25, wherein the seconddevolatilization chamber further comprises fluidization media, optionalsorbent, and bed solids.
 27. The feedstock conversion system accordingto claim 5, wherein the indirectly-heated hydrous devolatilizationsystem comprises one or more devolatilization chambers.
 28. Thefeedstock conversion system according to claim 27, wherein at least oneof the one or more devolatilization chambers comprises fluidizationmedia, optional sorbent, and bed solids.
 29. The feedstock conversionsystem according to claim 5, further comprising: a heat removal systemconfigured to cool the volatile reaction products above a dew point ofcondensable vapors contained therein; and/or a gas pressurization systemconfigured to provide pressurization of the volatile reaction products.